Concrete

We are using AI to developour process control

Published

2 years ago

February 14, 2024

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Dr Paula Carey, Co-Founder & Chief Scientific Officer, Carbon8 explains the impact of carbon capture technology at Carbon8 on the productivity, efficiency and circular economy of cement plants.

Tell us about your carbon capture technology.
Carbon8’s carbon capture utilisation and storage (CCUS) technology is known as Accelerated Carbonation (ACT). In the process, carbon dioxide derived directly from flue gas generated by a cement plant is reacted with calcium minerals within the cement by-pass or kiln dust produced by the same plant without the need for purification.

The reaction occurs at atmospheric temperatures and pressures over 20-30 minutes and can be engineered so that a carbon negative lightweight aggregate is produced, through granulation of the fine grained dusts.

The technology is delivered in a containerised plant (known as the CO2ntainer) with a small footprint that is plugged directly into the flue stack of the cement plant without affecting the cement manufacturing process.

What role can your technology play when implemented in a carbon intensive industry like the cement industry?
The amount of carbon dioxide that is captured is limited by the amount of residue available, but the economics of our system means that a profit can be made for every tonne of CO2 captured without the need for subsidies, or large energy penalties or the use of expensive toxic chemicals such as amines. The process results in the sustainable management of an industrial residue that might otherwise be destined for landfill and produces a low carbon product for the construction industry reducing the need for the extraction of natural aggregate.

What is the impact of your technology on the productivity and cost of cement manufacturing?
The installation of our technology has no effect on the productivity of the cement plant, it has a low energy requirement and its installation adds to the bottom line of the cement production.

How does your technology impact the energy efficiency of a cement plant?
Because our technology operates at atmospheric temperatures and pressures, it has a low energy demand and does not have an impact on the efficiency of the cement plant.

How does your tech support the circular economy?
Carbon8’s technology produces a carbon negative, lightweight aggregate from an industrial residue, breaking the route to landfill disposal and producing a sustainable product for the construction industry that replaces the need for the extraction of natural virgin aggregate. On our website – www.carbon8.co.uk – we describe ourselves as a “circular impact company

What are the major challenges in implementation and execution of your technology?
Because the amount of CO2 captured is relatively small compared with large-scale, expensive carbon capture projects, it has been more challenging to demonstrate the economic and environmental benefits of deploying and operating our technology within the global cement industry. A Vicat cement plant in France has been using our CO2tainer since 2020, after successful trials with CRH in Canada and Hanson (now part of Heidelberg Cement Group) in the UK.

The variability of the waste streams that are available to Carbon8 also raises a challenge; every cement works is slightly different and demands a unique solution in terms of mix design for our process.

What innovations can the world expect from Carbon8 in the near future?
We are using AI to develop our process control to overcome the variability of the residues that are generated by the different hard-to-abate industries, and so facilitate the deployment of ACT solutions into other sectors, like Energy From Waste, biomass and steel.

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Concrete

AFCM Unveils 2035 Regional Decarbonisation Roadmap for Cement Sector

AFCM launches world’s first regional decarbonisation plan for cement at Brunei meet.

Published

3 days ago

December 5, 2025

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The ASEAN Federation of Cement Manufacturers (AFCM) has formally launched the 2035 AFCM Decarbonisation Roadmap, becoming the first regional bloc in the world to introduce a unified decarbonisation strategy for the cement sector. The announcement was made at the 46th AFCM Council Meeting in Brunei Darussalam, chaired by Dr Chana Poomee, and attended by leaders and representatives of cement associations from all eight AFCM member countries. The launch comes as global attention intensifies ahead of COP30 in Brazil, where climate action is expected to be a central priority.

Cement production remains integral to infrastructure and economic development across the ASEAN region, yet it is also a major contributor to CO? emissions. The 2035 AFCM Decarbonisation Roadmap signals a collective regional commitment to accelerating emissions reduction in alignment with national climate policies and global sustainability goals, reinforcing AFCM’s leadership in the transition to low carbon cement production.

Dr Chana Poomee, AFCM President and Chairman of the Thai Cement Manufacturers Association (TCMA), described the roadmap as a landmark achievement for the region’s cement industry. He noted that the shared framework would support systematic CO? reduction, strengthen regional competitiveness and enhance ASEAN’s contribution to global climate objectives.

Developed with strong support from the Global Cement and Concrete Association (GCCA), the 2035 Roadmap sets out a comprehensive transition pathway anchored around four strategic pillars:

• Expansion of low carbon cement enabled by performance-based standards;

• Transition to clean and renewable energy across production processes, alongside improved thermal and electrical efficiency;

• Deployment of advanced decarbonisation technologies, including Carbon Capture, Utilisation and Storage (CCUS); and

• Development of new supplementary cementitious materials to support next-generation low carbon cement products.

Dr Chana urged all AFCM members to treat the roadmap as a coordinated regional strategy for sustainable growth. At the ASEAN level, the measures outlined have the potential to reduce up to 38 million tonnes of CO2 by 2035. While the roadmap sets a collective vision, it acknowledges the diversity of national conditions, recognising that each member country will set its own targets based on regulatory frameworks, industrial maturity and technological capacity. One key early-action priority is the reduction and phasedown of Ordinary Portland Cement (OPC), providing an immediate opportunity for substantial emissions cuts.

Cement associations from Brunei Darussalam, Cambodia, Indonesia, Malaysia, the Philippines, Singapore, Thailand and Vietnam expressed strong support for the roadmap and reaffirmed their commitment to advancing decarbonisation within their national contexts. Members emphasised the need for supportive policies, expanded use of alternative fuels, improved energy efficiency, accelerated adoption of advanced technologies and greater promotion of low carbon cement and concrete solutions. They also recognised that specific decarbonisation pathways will vary based on each country’s energy mix, material availability, policy environment and market readiness.

“The 2035 AFCM Decarbonisation Roadmap presents a significant opportunity to enhance regional competitiveness, drive sustainable development and unlock substantial economic benefits. Government support, including policy adaptation, will be essential for effective implementation. Through collaboration, innovation and collective action, AFCM can accelerate the adoption of low carbon technologies, attract green investment, create new economic opportunities and build a resilient, future-ready cement industry that contributes meaningfully to global decarbonisation,” Dr Chana concluded.

The issuer is solely responsible for the content of this announcement.

Concrete

Cement Makers Positive on H2 Demand Outlook

Major producers expect stronger sales in the second half of FY26.

Published

5 days ago

December 3, 2025

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The leading cement producers have posted high single-digit volume growth and better sales realisation in the July–September quarter, setting a positive tone for the second half of FY26. Companies are upbeat on demand prospects, supported by a strong housing sector and continued government spending on major infrastructure projects.

UltraTech, Ambuja Cement, Shree Cement, Dalmia Bharat and Nuvoco Vistas recorded revenue growth of up to 18 per cent in the September quarter. The rise was driven by firm realisations, softer input costs and an increased share of premium products.

With coal prices easing and diesel rates remaining stable year-on-year, companies expect margins to improve further in the coming months despite a rise in petcoke costs. In recent earnings calls, cement makers highlighted that the individual home builders segment across rural and urban markets is likely to drive demand, aided by favourable monsoon conditions, recent tax benefits and GST reforms.

Concrete

Fornnax Unveils the World’s Largest NPD and Demo Centre to Accelerate Global Recycling Innovation

Published

5 days ago

December 3, 2025

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A 12-acre innovation campus enables Fornnax to design, test and validate high-performance recycling solutions at global standards in record time.

Fornnax has launched one of the world’s largest New Product Development (NPD) centres and demo plants, spanning more than 12 acres, marking a major step toward its vision of becoming a global recycling technology leader by 2030. Designed to accelerate real-world innovation, the facility will enable faster product design cycles, large-scale performance validation, and more reliable equipment for high-demand recycling applications.

At the core of the new campus is a live demo plant engineered to support application-specific testing. Fornnax will use this facility to upgrade its entire line of shredders and granulators—enhancing capacity, improving energy efficiency, and reducing downtime. With controlled test environments, machines can be validated for 3,000 to 15,000 hours of operation, ensuring real-world durability and high availability of 18–20 hours per day. This approach gives customers proven performance data before deployment.

“Innovation in product development is the key to becoming a global leader,” said Jignesh Kundariya, Director and CEO of Fornnax. “With this facility, we can design, test and validate new technologies in 6–8 months, compared to 4–5 years in a customer’s plant. Every machine will undergo rigorous Engineering Build (EB) and Manufacturing Build (MB) testing in line with international standards.”

Engineering Excellence Powered by Gate Review Methodology

Fornnax’s NPD framework follows a structured Gate Review Process, ensuring precision and discipline at every step. Projects begin with market research and ideation led by Sales and Marketing, followed by strategic review from the Leadership Team. Detailed engineering is then developed by the Design Team and evaluated by Manufacturing, Service and Safety before approval. A functional prototype is built and tested for 6–8 months, after which the design is optimised for mass production and commercial rollout.

Open-Door Customer Demonstration and Material Testing

The facility features an open-door demonstration model, allowing customers to bring their actual materials and test multiple machines under varied operating conditions. Clients can evaluate performance parameters, compare configurations and make informed purchasing decisions without operational risk.

The centre will also advance research into emerging sectors including E-waste, cables, lithium-ion batteries and niche heterogeneous waste streams. Highly qualified engineering and R&D teams will conduct feasibility studies and performance analysis to develop customised solutions for unfamiliar or challenging materials. This capability reinforces Fornnax’s reputation as a solution-oriented technology provider capable of solving real recycling problems.

Developing Global Recycling Talent

Beyond technology, the facility also houses a comprehensive OEM training centre. It will prepare operators and maintenance technicians for real-world plant conditions. Trainees will gain hands-on experience in assembly, disassembly and grinding operations before deployment at customer sites. Post-training, they will serve as skilled support professionals for Fornnax installations. The company will also deliver corporate training programs for international and domestic clients to enable optimal operation, swift troubleshooting and high-availability performance.

A Roadmap to Capture Global Demand

Fornnax plans to scale its offerings in response to high-growth verticals including Tyre recycling, Municipal Solid Waste (MSW), E-waste, Cable and Aluminium recycling. The company is also preparing solutions for new opportunities such as Auto Shredder Residue (ASR) and Lithium-Ion Battery recovery. With research, training, validation and customer engagement housed under one roof, Fornnax is laying the foundation for the next generation of recycling technologies.

“Our goal is to empower customers with clarity and confidence before they invest,” added Kundariya. “This facility allows them to test their own materials, compare equipment and see real performance. It’s not just about selling machines—it’s about building trust through transparency and delivering solutions that work.”

With this milestone, Fornnax reinforces its long-term commitment to enabling industries worldwide with proven, future-ready recycling solutions rooted in innovation, engineering discipline and customer collaboration.